Fibrous Structures with Pore Volume Distribution for Absorbency
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Solution Overview
Problem
Current fibrous structures, such as paper towels, fail to provide consumers with optimal absorbency and strength properties simultaneously.
Innovation Solution
Development of fibrous structures with specific pore volume distributions and compositions, including a combination of filaments and solid additives, that exhibit a Vertical Full Sheet (VFS) value greater than 11 g/g, along with improved tensile modulus and tensile energy absorption, without the use of osmotic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fibrous structures are used, then manufacturing simplicity is maintained, but absorbency and strength properties are insufficient
Solution Approach 1:
The patent applies composite materials by combining different types of fibers (cellulosic fibers, synthetic fibers) with specific pore-forming additives and bonding agents to create a fibrous structure that achieves superior absorbency (VFS > 11 g/g) and strength properties simultaneously. The composite nature allows optimization of both functional performance and structural integrity.
Solution Approach 2:
The patent utilizes porous materials by incorporating pore-forming additives and creating a controlled pore volume distribution within the fibrous structure. This porous architecture enables enhanced absorbency capacity while maintaining structural strength through optimized pore size distribution and inter-fiber bonding.
2Quantity of substance
If osmotic materials are used to improve absorbency, then VFS increases, but product complexity and cost increase
Solution Approach 1:
The patent applies the extraction principle by deliberately excluding osmotic materials from the fibrous structure composition. Instead, it achieves high absorbency (VFS > 11 g/g) through alternative mechanisms involving pore-forming additives, optimized fiber composition, and controlled pore volume distribution, thereby simplifying material composition while maintaining superior absorbent capacity.
Solution Approach 2:
The patent applies parameter changes by optimizing the pore volume distribution parameters and fiber composition ratios to achieve enhanced absorbency without osmotic materials. Specific parameters such as pore radius distribution, fiber-to-additive ratios, and bonding agent concentrations are tuned to maximize VFS while maintaining structural simplicity.
3Quantity of substance
If pore volume is increased to improve absorbency, then VFS increases, but structural integrity may deteriorate
Solution Approach 1:
The patent applies local quality by creating a non-uniform pore volume distribution within the fibrous structure. Different regions of the material have optimized pore characteristics - with specific pore radius distributions tailored to local functional requirements. This allows high absorbency in pore-rich regions while maintaining structural integrity in load-bearing areas through optimized fiber density and bonding.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting fibrous structures demonstrate enhanced absorbency and strength properties, meeting consumer needs with improved absorbent capacity and surface drying characteristics, while maintaining structural integrity.
Implementation Method 1
a fibrous structure that exhibits a pore volume distribution such that less than about 20% of the total pore volume present in the fibrous structure exists in pores of radii of from about 1 μm to about 50 μm
Data Source
AI summary
A layered fibrous structure having a first layer including a co-formed fibrous structure containing a plurality of first filaments and a plurality of solid additives and a second layer different from the first layer, wherein the second layer includes a plurality of second filaments is provided.